Friction element for a damper disc having a friction adjusting element

ABSTRACT

A damper disc assembly having multiple embodiments. In one embodiment, spring seats are arranged at opposite ends of coil springs disposed between a power input rotary member and a power output rotary member. Each spring seat has a contacting surface with mutually perpendicular slanting portions. In another embodiment, a modified spring seat determines a phase or orientation of the power input rotary member with respect to the power output rotary member. In a third embodiment, a friction element is formed of resin and includes a friction adjusting element. The body portion of the friction element is made of resin and includes a friction generating surface that contacts a side surface of the sub-plate. The fiction adjusting element is provided in the friction generating surface of the body portion by molding and modifies the friction coefficient thereof. In a fourth embodiment, the friction element has a coating applied to a friction surface which modifies the friction coefficient.

This application is a division of application Ser. No. 08/681,426 filed on Jul. 23, 1996, now U.S. Pat. No. 5,954,585.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a damper disc assembly that employs both elastic members and friction members for dampening vibration. In particular the invention relates to an improved friction member and improved spring seats used with the elastic members.

2. Description of the Related Art

A clutch disc assembly for use in, for example, an automotive vehicle is typically provided with a disc-like power input plate, an power output hub formed with a radially extending flange, and coil springs disposed between the power input plate and the power output hub so as to limit the relative displacement between them. Alternatively, a separate hub/intermediate plate type damper disc assembly may also be provided. In this type of damper disc assembly, the conventional flange portion is separated from the hub portion and coil springs of low rigidity couple the separated flange and the hub portion.

In the separate hub/intermediate plate type damper disc assembly, the coil springs for coupling the separated flange and the hub portion are disposed within a receptacle formed in the flange portion of the hub side and a receptacle formed in the separated flange. Spring seats are provided on opposite sides of the coil spring. The end surface on the outer circumferential side in the circumferential direction of the spring seat is in contact with the receptacle portion of the flange portion of the hub side and the receptacle portion of the separated flange, respectively.

In the conventional spring seat used in the clutch disc assembly described above, the portion which the receptacles of the separated flange and the flange portion of the hub contact is made a slanting surface with V-shaped cross section. This slanting surface gradually lowers from the radially opposite sides to the inner circumferential side of the spring seat. In other words, the bottom of two of the slanting surfaces extends in the axial direction of the spring seat. The receptacle portion of the flange portion of the hub side and the receptacle portion of the separated flange extend towards the circumferential inner side and are in contact with each of two slanting surfaces, respectively.

When assembling a damper disc, the spring seat is typically already attached to opposite ends of the coil spring. The operators in the assembling line position the spring seats and coil spring within the space defined by the receptacle of the flange portion of the hub and the receptacle of the separated flange. At this time, the spring seat must be properly oriented for installation so that the slanting surface with V-shaped cross section corresponds to each slanting portion of receptacles of the flange portions of the hub side and the separated flange. In other words, the orientation of the spring seats is critical during installation. For example, if the spring seat turned by 90 degrees with respect to the correct orientation, it can not be installed. For this reason, the operators need to be careful about the orientation of the spring seats during installation. The necessity of proper orientation is an opportunity for error and may contribute to operational inefficiencies during assembly.

In other clutch disc assemblies a disc-like power input plate is provided along with a power output hub having a flange integral with its outer circumferential portion, and coil springs disposed between the power input plate and the flange so as to limit the relative displacement therebetween. The flange is provided with window holes formed by, for instance, die-cutting for receiving coil springs. The circumferentially opposite ends of the coil springs are in contact with the respective edge of the window hole. Support portions for supporting the circumferencially opposite ends of the coil spring is formed on the power input plate. With this configuration, when the power input plate are rotated, the torque is transmitted to the hub through the coil springs.

Alternatively, a separate hub/intermediate plate type clutch disc assembly have also been provided. In this type of clutch disc assembly, the conventional flange portion is separated from the hub portion and is couple to it by mean of the coil springs. In this type of clutch disc assembly, a larger twist angular displacement can be produced, and further, two levels of the characteristics of torsion can be obtained. A pair of the spring seats is disposed on the opposite ends of the small coil spring. The flange portion and the hub portion are provided with gear teeth which are circumferentially spaced apart from each other and the gear teeth of the flange portion and the gear teeth of the hub engage together with each other.

In the above described clutch disc assembly described above, the gear teeth of the hub portion are offset toward on the negative side (in the direction opposite to the rotational direction) by positioning off center between each of the gear teeth of the flange portion in a torsion free state. In other words, the amount of twist angular displacement of the hub portion with respect to the flange portion is larger on the positive side (in the rotational direction) and smaller on the negative side.

Such a configuration, under certain conditions, causes unpleasant sounds. It is possible to reduce these sounds by altering the characteristics of twist angular displacement depending on the type/model of the automotive vehicles. Altering the characteristics of twist angular displacement can be carried out by modifying the configurations of the flange portion and the hub portion, however, the production costs associated with manufacturing modified parts is prohibitive.

The above described clutch disc assembly also includes a hysteresis torque generating mechanism which includes friction elements which can be is pressing contact with the flange of hub and conical springs for pressing the friction elements against the flange.

It is desirable that the friction elements of the hysteresis torque generating mechanism are not rotatable relative to either one of the power input plate or the flange for stabilizing the hysteresis torque. Further, in view of operation efficiency, it is desirable that the hysteresis torque generating mechanism is integrally attached to either one of the power input plate or the power output hub.

The friction element with engaging portion engagable with the power input plate and prohibiting the relative rotation with respect to it has been provided. In this device, the friction element and conical spring are integrally mounted to the power input plate by means of the engaging portion.

With this arrangement, the friction element always rotates relative to the power output hub during operation, so that the hysteresis torque generated is stabilized. Further, since the friction element and conical spring are integrally mounted to the power input plate, the devices are portable as one unit, thereby enhancing operation efficiency.

The engaging portion of the friction element described above is elastic and its inter-fitting portion which axially extends is configured to be inter-fitted into the aperture formed on the power input plate. For this reason, the friction element of this type is normally formed by resin molding.

However, since the friction element of resin generally has a low friction coefficient, the sufficient amount of the friction force can not be obtained and, especially, the shock upon speedup/slowdown can not be efficiently absorbed. Also, in the initial condition, since the friction elements do not uniformly contact the power input plate, the friction coefficient becomes unstable. As a result, the desirable amount of the hysteresis torque can not be obtained.

SUMMARY OF THE INVENTION

One object of the present invention is to reduce the possibility of errors during assembly of a damper disc and its components.

Another object of the present invention is to alter the twist angular displacement of the damper mechanism.

Another object of the present invention to achieve a higher coefficient from a friction element of made of a resin material.

Another object of the present invention to provide a friction element made of a resin material with a stable friction coefficient.

In one aspect of the present invention, a spring seat is used with an elastic member in a damper disc assembly. The spring seat includes a spring seat body having a receiving surface for receiving the elastic member and a contacting surface for engaging a damper disc assembly plate member, the contacting surface formed with at least one slanting portion having a generally V-shaped cross section. The slanting portion is configured for installation of the spring seat body and the elastic member into a damper disc assembly in predetermined positions with the contacting surface in engagement with the damper disc assembly plate member.

Preferably, there are at least two of the slanting portions, the slanting portions being perpendicular to one another, the slanting portions being configured for installation of the spring seat body and the elastic member into the damper disc assembly in any one of four predetermined perpendicular positions.

Preferably, the spring seat body is formed with a generally square shape and the slanting portions extend so as to divide the contacting surface into four sections.

Preferably, the spring seat body is formed with a first support portion and a second support portion, the second support portion having an axial thickness greater than an axial thickness of the first support portion.

Preferably, the slanting portions are configured for installation of the spring seat body and the elastic member into the damper disc assembly in one of two predetermined perpendicular positions with the contacting surface in engagement with the damper disc assembly plate member.

Preferably, the elastic member comprises a coil spring.

In accordance with another aspect of the present invention, a damper disc assembly includes a power input rotary member formed with a first recess on an inner radial surface thereof and a power output rotary member formed with a second recess on an outer radial surface thereof, the power output rotary member disposed adjacent to the power input rotary member for relative rotary displacement with respect thereto. An elastic member is disposed within both the first and second recesses. A seat body is formed with a first support portion and a second support portion, the second support portion having an axial thickness greater than an axial thickness of the first support portion. A first seat body is disposed at first end of the elastic member and a second seat body is disposed at a second end of the elastic member within the first and second recesses elastically coupling the power input rotary member and the power output rotary member. Where the first support portion of the first seat body is in a radially outward position and the second support portion of the second seat body is in a corresponding radially outward position, the first recess is angularly offset from the second recess.

Preferably, the elastic member is a coil spring.

Preferably, the power input rotary member is further formed with a plurality of first protrusions which extend radially inwardly and the power output rotary member is formed with a plurality of second protrusions which extend radially outwardly such that the first and second protrusions extend between one another defining a predetermined gap therebetween in the circumferential direction.

In accordance with another aspect of the present invention, a method for altering the characteristics of torsion of the damper mechanism are provided. In the method, a power input rotary element is provided and a power output rotary element is disposed so as to be rotatable relative to the power input rotary element by a predetermined angle. A coil spring is disposed between the power input rotary element and the power output rotary element. Spring seats are disposed on the opposite ends of the coil spring and are supported by the power input rotary member and the power output rotary element. The method includes altering the phase of the power input rotary element with respect to the power output rotary element in a torsion free state by shifting the height of a first supported surface supported by the power input rotary element with respect to that of a second supported surface supported by the power output rotary element.

In accordance with another aspect of the present invention, a friction element for a damper disc assembly is disposed between a power input element and a power output element where the friction element undergoes sliding movement in response to relative rotation of the power input element and the power output element. The friction element includes a body portion formed of a resin material having a friction generating surface formed on one side thereof and an engaging portion is formed integrally with the body portion on a second side of the body portion, the engaging portion extending away from the friction generating surface. A friction adjusting element is provided on at least a portion of the friction generating surface of the body portion, the friction adjusting element formed of a material having a friction coefficient different from that of the body portion.

Preferably, the friction adjusting element has friction coefficient higher than that of the body portion.

Preferably, the friction adjusting element is molded with the body portion.

Preferably, the friction adjusting element is a coating formed on the friction generating surface.

Preferably, the engaging portion includes an elastic inter-fit portion that is elastically deformable.

In accordance with another aspect of the present invention, a damper disc assembly includes a power input element and a power output element disposed adjacent to the power input element, the power output element being relatively rotatable with respect to the power input element, and the power output element formed with having a flange which extends radially outward parallel to at least a portion of the power output element. The damper disc assembly also includes an elastic member for elastically coupling the power input element and the power output element in the circumferential direction and a friction element disposed between the power output element and the power input element, the friction element formed with a friction generating surface in contact with at least one of the power output element and the power input element, the friction element also formed with engaging portion engaged with one of the power output element and the power input element for rotation therewith, and a friction adjusting element provided on at least a portion of the friction generating surface, the friction adjusting element formed of a material having a coefficient of friction different from that of the friction element. A spring element is also provided for urging the friction generating surface of the friction element against one of the power output element and the power input element.

Preferably, the friction element formed of a resin material.

Preferably, the friction adjusting element is formed of a textile blend of rubber based material, a textile blend of resin material, a fiber-glass re-inforced material or a ceramic material.

Preferably, the friction adjusting element is formed of a textile blend of rubber based material, or a textile blend of resin material or a fiber-glass re-inforced material or a ceramic material.

Preferably, the fiction adjusting element is molded into the friction generating surface and has a higher friction coefficient than the friction element.

Preferably, the fiction adjusting element is a coating for adjusting the friction coefficient formed on the friction generating surface.

Preferably, the coating includes a flame spray coating having phenolic resin.

Preferably, the coating includes a flame spray coating having zinc.

Preferably, the coating includes copper.

In accordance with one of the aspects of the present invention, assembly of a damper disc assembly and installation of the spring seats is made simpler and manufacturing more reliable operators can bring anyone of the plurality of the slanting portions with V-shaped cross section of the spring seat into contact with the power input rotary member and the power output rotary member.

In another of the aspects of the present invention, it is possible alter the phase of the power input rotary member with respect to the power output rotary member, with respect to relative positions in a torsion free state, by shifting the positions of the first and second supported surfaces of the spring seat members.

In another of the aspects of the present invention, it is possible to adjust the friction coefficient of the friction generating surface by the inclusion of the friction adjusting element in the friction generating surface, so that it is possible to obtain the higher friction coefficient. It is also possible to form a coating on the friction generating surface to alter the friction characteristics of the damper disc assembly.

These and other objects, features, aspects and advantages of the present invention will become more fully apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings where like reference numerals denote corresponding parts throughout, in which:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side sectional view showing a clutch disc assembly in accordance with a first embodiment of the present invention;

FIG. 2 is a part elevation, part cutaway view of the clutch disc assembly depicted in FIG. 1, looking in the direction of the arrow II of FIG. 1, and FIG. 1 is a section view taken along the line I—I in FIG. 2;

FIG. 3 is fragmentary view of the clutch disc assembly showing the portion A in FIG. 1, on a slightly enlarged scale, with details of a friction mechanism of the clutch disc assembly;

FIG. 4 is a fragmentary view of a portion of FIG. 2, on a slightly enlarged scale, showing details of an elastic member and corresponding spring seats of the clutch disc assembly;

FIG. 5 is a side view of the spring seat depicted in FIG. 4, shown removed from the clutch disc assembly;

FIG. 6 is an end view of the spring seat depicted in FIG. 5, shown removed from the clutch disc assembly, looking in the direction of the arrow VI of FIG. 5;

FIG. 7 is a side sectional view showing a clutch disc assembly, similar to FIG. 1, in accordance with a second embodiment of the present invention and FIG. 7 is a section view taken along the line VII—VII in FIG. 8;

FIG. 8 is a part elevation, part cutaway view of the clutch disc assembly depicted in FIG. 7, looking in the direction of the arrow VIII of FIG. 7,

FIG. 9 is an end view of a hub shown removed from the clutch disc assembly depicted in FIGS. 7 and 9, shown on a slightly enlarged scale;

FIG. 10 is a cross sectional view of the hub taken along the line X—X in FIG. 9;

FIG. 11 is a fragmentary view of the clutch disc assembly showing the portion A in FIG. 7 on a slightly enlarged scale, with details of a friction mechanism of the clutch disc assembly;

FIG. 12 is an elevational view of a first friction washer shown removed from the friction mechanism depicted in FIG. 11;

FIG. 13 is a cross sectional view of the first friction washer taken along the line XIII—XIII in FIG. 12, looking in the direction of the arrows;

FIG. 14 is an elevational view of a second friction washer shown removed from the friction mechanism depicted in FIG. 11;

FIG. 15 is a cross sectional view of the second friction washer taken along the line XV—XV in FIG. 14, looking in the direction of the arrows;

FIG. 16 is a cross sectional view of the second friction washer taken along the line XVI—XVI in FIG. 14, looking in the direction of the arrows;

FIG. 17 is a fragmentary view of the hub and a sub-plate of the clutch disc assembly depicted in FIGS. 7 and 8, showing the engagement between the hub and the sub-plate and coil springs disposed therebetween;

FIG. 18 is a part elevation, part cutaway view similar to FIGS. 2 and 8, of a clutch disc assembly in accordance with a third embodiment of the present invention;

FIG. 19 is fragmentary view of the clutch disc assembly, similar to FIGS. 3 and 11, showing a friction mechanism of the third embodiment of the clutch disc assembly depicted in FIG. 18, on a slightly enlarged scale;

FIG. 20 is a cross sectional view, similar to FIG. 15, of a second friction washer shown removed from the friction mechanism depicted in FIG. 19;

FIG. 21 is a cross sectional view, similar to FIG. 16, of the second friction washer shown removed from the friction mechanism depicted in FIG. 19;

FIG. 22 is an elevational view of a first conical spring shown removed from the friction mechanism depicted in FIG. 19;

FIG. 23 is an elevational view of a second conical spring shown removed from the friction mechanism depicted in FIG. 19;

FIGS. 24 and 25 are fragmentary, cross sectional views of the friction mechanism depicted in FIG. 19, shown on a further enlarged scale;

FIG. 26, is a fragmentary, cross sectional view, similar to FIGS. 24 and 25, showing a friction mechanism in accordance with a fourth embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

First Embodiment

A clutch disc assembly 1 according to one embodiment of the present invention is shown in FIG. 1. The clutch disc assembly 1 is used to transmit a torque from an engine (not shown) located on the left side of FIG. 1 to a transmission (not shown) located on the right side of FIG. 1. In FIG. 1, line O—O designates a rotary axis of the clutch disc assembly 1.

The clutch disc assembly 1 includes a hub 2 which serves as a power output element, a clutch disc 3 and a retaining plate 4 which together serve as power input elements, a sub-plate 5 which serves as an intermediate element, small coil springs 6 disposed between the sub-plate 5 and the hub 2 so as to limit the relative displacement between them, large coil springs 7 disposed between the plates 3 and 4 and the sub-plate 5 so as to limit the relative displacement between them, and a friction resistance generating mechanism 8 to produce the predetermined amount of hysteresis torque upon the relative rotation between the plates 3 and 4 and the hub 2. The large coil springs 7 include a first spring assembly 7 a and a second spring assembly 7 b.

A hub 2 which is connectable to a shaft (not shown) of the transmission is disposed at the center of the clutch disc assembly 1. The hub 2 includes a cylindrical boss 2 a which axially extends and a flange portion 2 b integral with the outer circumference of the boss 2 a. The spline hole 2 f which is spline-engaged with the shaft (not shown) of the transmission is formed on the inner circumferential side of the boss 2 a. The flange portion 2 b, as shown in FIG. 2, is provided with a plurality of outer circumferencial gear teeth 2 c which extend radially outwardly. Inner circumferencial gear teeth 5 d formed on the inner circumferential portion of the separated flange 5 correspond to the portions between each of the outer circumferencial gear teeth 2 c. A predetermined gap is provided between each of the outer circumferencial gear teeth 2 c and the inner circumferencial gear teeth 5 d in the circumferential direction.

As shown in FIG. 4, receptacles 2 d are formed at two diametrically opposite positions in the flange portion 2 b. The support portions 2 e formed on the opposite sides in the circumferential direction of the receptacles 2 d are circumferentially tapered.

A sub-plate 5 (a separated flange) is disposed on the outer circumference of the flange portion 2 b of the hub 2 and is disposed in the same plane as the flange portion 2 b of the hub 2. The sub-plate 5 is a disc-shaped plate. The sub-plate 5, as is apparent from FIG. 2, includes four extending portions 5 a which extend radially outwardly. Each of the extending portions 5 a is provided with a circumferentially extending window hole 5 b. Outside cutaways 5 c are provided between each of the extending portions 5 a.

As shown in FIG. 4, a small spring 6, a pair of spring seats 32 and a rubber float 31 are disposed within the space defined by the receptacles 2 d and 5 e. As is apparent from FIG. 5 and FIG. 6, the spring seats 32 are composed of a spring seat body 33 of square-shaped having a predetermined thickness and a project portion 34 extending from the spring seat body 33. The project portion 34 is formed on a receiving surface 35 of the spring seat body 33. The small coil spring 6 is in contact with the receiving surface 35 and the project portion 34 extends into the small coil spring 6. A contacting surface 36 which is the other side of the receiving surface 35 of the spring seat body 33 is provided with slanting portions 37 and 38 with V-shaped cross sections, the slanting portions 37 and 38 being mutually perpendicular. The contacting surface 36 is divided into four square sections by the slanting portions 37 and 38. The slanting portions 37 and 38 slant so as to become lower from the middle of each four sides to the center of the contacting surface 36. With this arrangement, the support portions 2 e and 5 f are contactable to either one of the slanting portions 37 or 38.

In the conventional spring seat, the attaching direction of the spring seat is fixed and the spring seat had to properly be set so as the slanting surface with V-shaped cross section to properly be contact to the support portion. That is, the spring seat had to be set so as the borderline of the slanting surface with V-shaped cross section to extend in the axial direction and just two of four sides of the square can be located in the upper portion. In the spring seat in accordance with the present invention, anyone of four sides of the square can be located in the upper portion, thereby enhancing operation efficiency in attaching the spring seats.

A rubber float 31 (FIG. 4) is disposed inside the coil spring 6.

A clutch plate 3 and retaining plate 4 are disposed on opposite sides of the sub-plate 5. The plates 3 and 4 are substantially a pair of disc-like plates and are rotatably disposed on the outer peripheral side of the boss 2 a of the hub 2. The plates 3 and 4 are fixed to each other at their outer peripheral portions by contact pins 11. Each pin 11 passes through the outside cutaway 5 c formed in the sub-plate 5. A predetermined space is kept in the circumferential direction between the contact pins 11 and the outside cutaway 5 c, so that the plates 3, 4 and the sub-plate 5 are rotatable relative to each other.

A frictional surface portion 10 is disposed on the outer periphery of the clutch disc 3. The frictional surface portion 10 includes annular cushioning plates 12 and a plurality of frictional facings 13. The annular portion 12 a of the cushioning plate 12 is fixed to the clutch plate 3 by the contact pin 11. A plurality of cushioning portions 12 b are formed on the outer peripheral side of the cushioning plate 12. Frictional facings 13 are fixed on the opposite sides of the cushioning portion 12 b.

The clutch plate 3 and the retaining plate 4 are provided with window holes 3 a and 4 a at the positions corresponding to the window holes 5 b of the sub-plate 5, respectively. Holding portions 3 b and 4 b raised axially outwardly are formed at axially opposite sides of each of the window holes 3 a and 4 a.

Four large springs 7 are used in this clutch disc assembly 1, and each of them is disposed within the window holes 5 b of the sub-plate 5. Small coil springs are disposed inside the large coil springs 7 which are located at two diametrically opposite positions. The axial movement of the large springs 7 is restrained by the holding portion 4 b of the retaining plate 4 and the holding portion 3 b of the clutch plate 3.

The friction resistance generating mechanism 8 will now be described.

The friction resistance generating mechanism 8 is composed of the annular members each of which is disposed between the inner peripheral portion of the clutch plate 3 and the inner peripheral portion of the retaining plate 4 in the axial direction as well as on the outer peripheral side of the boss 2 a.

The members in the friction resistance generating mechanism 8 include a first friction washer 14, a second friction washer 15, a first conical spring 16, a second conical spring 17 and a third friction washer 18. An annular extending portion 18 b which axially extends toward the engine side is formed on the inner circumferential portion of the third friction washer 18.

The first friction washer 14 is a disc-like member of resin. The first friction washer 14 is in contact with the a side surface on the transmission side of the flange portion 2 b of the hub 2. The first conical spring 16 is disposed in a compressed state between the first friction washer 14 and the retaining plate 4 in the axial direction.

The second friction washer 15 is a disc-like member of resin and is disposed on the outer peripheral side of the first friction washer 14. The second friction washer 15 is in contact with the inner peripheral end surface of the sub-plate 5. The first friction washer 14 is shown removed from the clutch disc assembly 1 in FIGS. 12 and 13. The second friction washer 15 is engaged with the first friction washer 14 so as not to rotate relative to it. The second friction washer 15 is provided with a projection having snap a projection 15 c (shown in FIG. 1) which is engagable to the retaining plate 4 so as not to rotate relative to it but to be movable to it in axial directions. The second friction washer 15 is shown removed from the clutch disc assembly 1 in FIGS. 15 and 16. The second conical spring 17 is disposed in a compressed state between the second friction washer 15 and the retaining plate 4 in the axial direction.

The third friction washer 18 is disposed between the inner peripheral portion of the clutch plate 3 and the flange portion 2 b of the hub 2 and the inner peripheral edge of the sub-plate 5 in the axial direction.

The operation of the clutch disc assembly 1 will now be described.

When the frictional facing 13 comes into pressing contact with a flywheel (not shown) on the engine side, the torque from flywheel on the engine side is transmitted to the clutch plate 3 and the retaining plate 4. This torque is transmitted to the hub 2 through the large coil spring 7, the sub-plate 5 and the small spring 6 and is further outputed to the shaft (not shown) on the transmission side.

Transmitting the twist vibration from a flywheel (not shown) on the engine side to the clutch disc assembly 1 brings about the regular relative rotation between the plates 3, 4 and the hub 2. At this time, the small springs 6 and the large springs 7 are compressed to produce hysteresis torque in the friction resistance generating mechanism 8.

The characteristics of torsion will now be described.

When the torsional displacement between the flywheel on the engine side and the clutch disc assembly 1 is small, the plates 3, 4 rotate together with the sub-plate 5. This causes the hub 2 to rotate relative to them. In this case, the small coil spring 6 is compressed in the circumferential direction, and the first friction washer 14 and the third friction washer 18 is slidably moved along the flange portion 2 b of the hub 2. When the torsional displacement between them becomes larger, the rubber float 31 is brought into pressing contact with the spring seat 32. This movement will be continued until the outside gear teeth 2 c contact the inside gear teeth 5 d. As a result, desired characteristics of low rigidity/low hysteresis torque can be obtained.

When the torsional displacement between the flywheel on the engine side and the clutch disc assembly 1 is large, the sub-plate 5 rotate together with the hub 2. This causes the plates 3,4 to rotate relative to them. In this case, the large coil spring 7 is compressed and the first friction washer 14 is slidably moved along the flange portion 2 b of the hub 2, the second friction washer 15 is slidably moved along the inner circumferential side surface of the sub-plate 5, and further, the third friction washer 18 is slidably moved along the flange portion 2 b of the hub 2 and the inner circumferential portion of the sub-plate 5. This movement will be continued until the contact pin 11 contacts the cutaway 5 c. Resultantly, the characteristics of high rigidity/high hysteresis torque can be obtained.

ADVANTAGES OF THE INVENTION

In the spring seat in accordance with one aspect of the present invention, during assembly, the assembling operators can bring any one of the plurality of the slanting portions with V-shaped cross section of the spring seat into contact with the power input rotary plate and the power output rotary plate. In other words, the orientation of the spring seat is no longer as critical a factor as in the prior art, thereby enhancing operational efficiency in assembling the damper disc assembly and inserting the spring seats.

In the spring seat in accordance with another aspect of the present invention, any one of four orientations of the spring seats may be considered during assembly of the damper disc assembly thereby enhancing operational efficiency in assembling the damper disc assembly.

Second Embodiment

A clutch disc assembly 1′ according to a second embodiment of the present invention is shown in FIG. 7. The clutch disc assembly 1′ is used to selectively transmit torque from an engine (not shown) located on the left side of FIG. 7 to a transmission (not shown) located on the right side of FIG. 7. In FIG. 7, line O—O designates a rotary axis of the clutch disc assembly 1′. Also, R1 in FIG. 8 and FIG. 17 indicates a rotational direction of the clutch disc assembly 1′.

The clutch disc assembly 1′ includes a hub 2′ which serves as a power output element, a clutch disc 3 and a retaining plate 4 which serve as power input elements, a sub-plate 5 which serves as an intermediate element, small coil springs 6 disposed between the sub-plate 5 and the hub 2′ so as to limit the relative displacement between them, large coil springs 7 disposed between the plates 3,4 and the sub-plate 5 so as to limit the relative displacement between them, and a friction resistance generating mechanism 8 to produce the predetermined amount of friction force upon the relative rotation between the plates 3 and 4 and the hub 2′.

A hub 2′ which is connectable to a shaft (not shown) of the transmission is disposed at the center of the clutch disc assembly 1′. The hub 2′ includes a cylindrical boss 2 a which axially extends and a flange portion 2 b integral with the outer circumference of the boss 2 a. A plurality of protrusions 2 c are formed at regular intervals in the circumferential direction on the outer circumference of the flange portion 2 b. As shown in FIGS. 9 and 17, cutaways 2 d for receiving the circumferentially opposite ends of the small coil spring 6, described below, are formed at two diametrically opposite positions in the flange portion 2 b. Further, the spline hole 2 f which is spline-engaged with the shaft (not shown) of the transmission is formed on the inner circumferential side of the boss 2 a.

A sub-plate 5 is disposed on the outer circumferencial side of the flange portion 2 b of the hub 2′. The sub-plate 5 is a disc-shaped plate. The sub-plate 5, as is shown in FIG. 8, includes four extending portions 5 a which radially outwardly extend. Each of the extending portions 5 a is provided with a window hole 5 b which extend in the circumferential direction.

Outside cutaway 5 c are provided between each of the extending portions 5 a. Inwardly extending protrusions 5 d are formed on the inner circumferential side of the sub-plate 5 at the positions corresponding to the portions between each of the protrusions 2 c of the hub 2′. A predetermined space is provided between the protrusion 2 c and the inside protrusion 5 d, as is shown in both FIGS. 8 and 17. This allows the hub 2′ and the sub-plate 5 to rotate relative to each other by a predetermined angle.

As is shown in both FIGS. 8 and 17, inside receptacles 5 e are formed on the inner circumference of the sub-plate 5 at positions corresponding to the cutaways 2 d of the hub 2′. Small springs 6 are disposed within the space defined by the cutaways 2 d and the inside receptacles 5 e. Seat members 40 are disposed on the opposite ends of the small spring 6. As shown in detail in FIG. 17, the seat member 40 includes a seat portion 41 of the disc-shaped and an inserted portion 42 extending from the seat portion 41 to the inside of the small coil spring 6. The seat portion 41 includes a first support portion 43 and a second support portion 44 which extends in the circumferential direction further than the first support portion 43 in the circumferential direction. In other words, the second support portion 44 is thicker than the first support portion 43 extending away from the spring 6. In the seat member 40 on the R1 side, the first support portion 43 is supported by the inside receptacle 5 e and the second support portion 44 is supported by the cutaway 2 d, while in the seat member 40 on the R2 side, the first support portion 43 is supported by the cutaway 2 d and the second support portion 44 is supported by the inside receptacle 5 e. As a result, the phase of the cutaway 2 d is shifted on the R1 side with respect to that of the inside receptacle 5 e, as is explained in greater detail below. Also, with the configuration shown in FIG. 17, the protrusion 2 c of the hub 2′ in a torsion free state is disposed at a central position between each adjacent inwardly extending protrusions 5 d. Further, the hub 2′ can rotate relative to the sub-plate 5 from a torsion free state by a displacement angle of 5 degrees in either the R1 direction or the R2 direction.

It should be understood that the seat member 40 may include at least one slanting portion similar to the slanting portions 37 and 38 described above with respect to the first embodiment for retention of the seat member 40 within the receptacles 2 d and 5 e.

The phase, as mentioned above, refers to two related aspects of the hub 2′ and the sub-plate 5. Specifically, as is shown in FIG. 17, the inwardly extending protrusions 5 d and the protrusions 2 c are shaped such that the protrusions 2 c fit uniformly within the gaps between adjacent extending protrusions 5 d. In the second embodiment, the protrusions 2 c are centered between adjacent extending protrusions 5 d. However, in the first embodiment the protrusions 2 c are off-center between adjacent extending protrusions 5 d. The shift from being centered in the second embodiment to being off-center, as in the first embodiment, is a phase shift. Further, the inside receptacle 5 e and the cutaways 2 d have generally the same circumferential length but, in the second embodiment in FIG. 17, the inside receptacles se and the cutaways 2 d are offset from one another due to the orientation of the seat members 40, described above. However, in the first embodiment (FIG. 4) the inside receptacles 5 e and the cutaways 2 d are generally circumferentially aligned. The orientation of the seat members 40 have caused a phase shift between the inside receptacle 5 e and the cutaways 2 d in the second embodiment without any change in the orientation or re-design of the inside receptacle 5 e and the cutaways 2 d or the inwardly extending protrusions 5 d and the protrusions 2 c.

The shape and position of the inwardly extending protrusions 5 d and the protrusions 2 c are generally the same as in the first embodiment depicted in FIGS. 1-6. However, because of the shape and orientation of the seat members 40, the protrusions 5 d of the sub-plate 5 are no longer offset from the hub 2′, but the inside receptacle 5 e and the cutaways 2 d are offset, unlike the case with the first embodiment where the offset is between the respective protrusions. Hereinafter, the orientation of the seat members 41 as shown in FIG. 17 will be referred to as out-of-phase, since the first support portion 43 and the second support portion 44 are not symmetrically installed in the inside receptacle se and the cutaway 2 d. In an alternate condition (not shown but similar to that in the first embodiment) where the first support portion 43 and the second support portion 44 are symmetrically installed in the inside receptacle se and the cutaway 2 d will hereinafter be referred to as in-phase. Hence the term out-of-phase refers to the condition where the inside receptacle 5 e and the cutaway 2 d are not circumferentially aligned in a torsion free state. The term in-phase refers to the condition where the inside receptacle 5 e and the cutaway 2 d are circumferentially aligned in a torsion free state. Therefore, the first embodiment is in-phase and the second embodiment, as shown in FIG. 17 is out-of-phase. It should be appreciated that, with respect to the orientation shown in FIG. 17, if only one of the seat members 41 is reversed (rotated 180°) the phase of the second embodiment will be shifted to an in-phase condition.

If the second embodiment is shifted to an in-phase condition, the protrusion 2 c of the hub 2′ will be shifted toward the R2 direction between each of the inwardly extending protrusions 5 d of the sub-plate 5 in a torsion free state. In other words, the hub can rotate relative to the sub-plate 5 in a torsion free state by the angle of 7degrees on the R1 side while the angle of 3 degrees on the R2 side. That is, the preferred embodiment here effects the alteration of the characteristics of torsion of the conventional construction which includes the hub 2′ and the sub-plate 5 which are connected to each other through the small coil spring 6 by modifying the configuration of the seat member 40. In this manner, modifying the configuration of the seat member 40 can be carried out easier and less costlier than that of the changing the cutaway portion in the hub or in the receptacle portion of the sub-plate. Further, each of the seat members 40 has the same configuration thereby reducing the manufacturing cost.

The characteristics of the twist angular displacement to be set are not limited to this preferred embodiment but can be varied.

A clutch plate 3 and retaining plate 4 are disposed on opposite sides of the sub-plate 5. The plates 3 and 4 are substantially a pair of disc-like plates which are rotatably engaged with the outer periphery of boss 2 a of the hub 2′. The plates 3 and 4 are fixed to each other at their outer peripheral portions by contact pins 11. Each contact pin 11 passes through an outside cutaway 5 c of the sub-plate 5. A predetermined space is kept in the circumferential direction between the contact pin 11 and the outside cutaway 5 c, so that the plates 3, 4 and the sub-plate 5 are rotatable relative to each other.

A frictional surface portion 10 is disposed on the outer peripheral portion of the clutch disc 3. The frictional surface portion 10 includes an annular cushioning plates 12 and a plurality of frictional facings 13. An annular portion 12 a of the cushioning plates 12 is fixed to the clutch plate 3 by the contact pin 11. A plurality of cushioning portions 12 b are formed on the outer peripheral side of the cushioning plates 12. Frictional facings 13 are fixed on the opposite sides of the cushioning portion 12 b. A flywheel (not shown) on the engine side is disposed on the left side of FIG. 7 with respect to the frictional facings 13. When the frictional facings 13 are in pressing contact with the flywheel by means of the pressure plate (not shown), the torque on the engine side is inputed to the clutch disc assembly 1′.

The clutch plate 3 and the retaining plate 4 are provided with window holes 3 a and 4 a at the positions corresponding to the window holes 5 b of the sub-plate 5, respectively. The large coil spring 7 is disposed within the space defined by the window holes 3 a and 4 a. Holding portions 3 b and 4 b raised axially outwardly on the radially opposite sides of respective window hole 3 a and 4 a.

Total four large coil springs 7 are used in this clutch disc assembly 1′, and each of them is disposed within each of the window holes 5 b. A coil spring 58 of smaller diameter is disposed inside the large coil spring 7. The circumferential opposite ends of the coil springs 7 and 58 are in contact with the circumferential opposite ends of the respective window holes 5 b, 3 a and 4 a.

The radial movement and the axial movement of the large coil springs 7 described above are restricted by the holding portion 4 b of the retaining plate 4 and the holding portion 3 b of the clutch plate 3.

Four apertures 3 c and four apertures 4 c which are engaged with a portion of the friction resistance generating mechanism 8 (described below) are formed so as to be circumferentially spaced apart from one another on the inner side of the clutch plate 3 and the retaining plate 4, respectively.

The friction resistance generating mechanism 8 will now be described.

The friction resistance generating mechanism 8 is composed of the annular members each of which is disposed between the inner circumferential portion of the clutch plate 3 and the inner circumferential portion of the retaining plate 4 in the axial direction and on the outer peripheral side of the boss 2 a. The friction resistance generating mechanism 8 includes a first friction washer 14, a second friction washer 15, a first conical spring 16, a second conical spring 17 and a third friction washer 18.

The first friction washer 14 is a disc-like member made of a resin material. The inner circumferential edge of the first friction washer 14, as shown in FIG. 11, is adjacent to the boss 2 a. Also, one side surface of the first friction washer 14 is in contact with the flange portion 2 b of the hub 2′ and the side surfaces on the transmission side of the protrusion 2 c. The first friction washer 14, as shown in FIGS. 11, 12 and 13, includes a disc portion 14 a and an annular extending portion 14 b which extends from the inner circumferential side of the disc portion 14 a to the transmission side. The annular extending portion 14 b is provided with an annular groove 14 c on its transmission side. Four of radially outwardly extending projections 14 d are formed on the outer periphery of the disc portion 14 a.

The first conical spring 16 is disposed between the first friction washer 14 and the retaining plate 4 in the axial direction, as is shown in FIGS. 8 and 11. The outer circumferential end of the first conical spring 16 is supported by the retaining plate 4 and the inner circumferential end of the first conical spring 16 is in contact with the annular groove 14 c formed on the annular extending portion 14 b of the first friction washer 14. The first conical spring 16 is disposed in a compressed state and urges the first friction washer 14 toward the flange portion 2 b and the protrusion 2 c of the hub 21. The conical spring 16 is provided with a plurality of cutaways 16 a on its outer circumference. These cutaways are provided for the purpose of restraining the variation of the urging force of the first conical spring 16 upon the deformation of the first conical spring due to the wear of the friction washer 14.

The second friction washer 15, as is apparent from FIGS. 14, 15 and 16, is a disc-like member, is generally disposed in the same plane as the first friction washer 14, as is shown in FIG. 11. The second friction washer 15 is concentric with the first friction washer 14 on the outer circumferential side of the first friction washer 14. The second friction washer 15 is composed of the same material and has generally the same friction coefficient as the first friction washer 14. The second friction washer 15 includes a disc portion 15 a and an annular extending portion 15 b which extends from the inner circumferential side of the disc portion 15 a to the transmission side. The side surface on the engine side of the disc portion 15 a is in contact with the inner circumferential end surface of the sub-plate 5. Four recesses 15 e are equidistantly formed in the circumferential direction on the end surface on the transmission side of the annular extending portion 15 b. The projection 14 d of the first friction washer 14 is engaged with the recess 15 e so as not to rotate relative to it in the circumferential direction but to be movable to it in axial directions. A predetermined space is provided between the projection 14 d and the recess 15 e. The annular extending portion 15 b is provided with four projections which extends towards the transmission side between each of the recesses 15 e. These projections include two snap projections 15 c and two bar-shaped projections 15 d. In this embodiment, the same kind of the projections are arranged so as to be facing to each other. The snap projection 15 c is divided into two sections by an axially extending slit and is provided with a hook-shaped snap at its tip end. The snap projection 15 c is engaged with the aperture 4 c formed on the retaining plate 4. The second washer 15 is difficult to remove from the retaining plate 4 in the axial direction by means of the snap portion formed on the snap projection 15 c. The bar-shaped projection 15 d is engaged with another aperture 4 c formed on the retaining plate 4.

The second conical spring 17 is disposed between the second friction washer 15 and the retaining plate 4 in the axial direction. The second conical spring 17 is provided with a plurality of cutaways on its inner periphery, as can be seen in FIG. 23. These cutaways are provide to restrain the variation of the urging force of the second conical spring 17 upon the its deformation due to the wear of the second washer 15. The second conical spring 17 is disposed in a compressed state. The outer circumferential end of the second conical spring 17 is in contact with the retaining plate 4 and the inner circumferential end of the second conical spring 17 or the projection 17 b is in contact with the side surface on the transmission side of the annular extending portion 15 b of the second friction washer 15. With this arrangement, the second conical spring 17 urges the second friction washer 15 toward the side surface on the transmission side of the sub-plate 5. At this time, the urging force of the second conical spring 17 is set to be larger than that of the first conical spring 16. The cutaways 17 a of the second conical spring 17 coincide with the snap projections 15 c, the bar-shaped projections 15 d and the recesses 15 e so as not to interfere with one another.

The third friction washer 18 is disposed between the inner circumferential portion of the clutch plate 3 and the flange portion 2 b of the hub 2′ and the inner circumferential end of the sub-plate 5, as is shown in FIG. 11. The third friction washer 18 is composed of generally the same material and has generally the same friction coefficient as the first friction washer 14 and the second friction washer 15. The side surface on the transmission side of the third friction washer 18 is in contact with the side surface of the flange portion 2 b and the side surface of the inner circumferential end portion of the sub-plate 5. Also, the side surface on the engine side of the third friction washer 18 is in contact with the clutch plate 3. The outer circumferential portion of the third friction washer 18 is provided with snap projections 18 a (see FIG. 7) which extend toward the engine side in the axial direction and are engaged with the apertures 3 c formed on the clutch plate 3. The snap projections 18 a are configured identical to the above mentioned snap projections 15 c of the second friction washer 15. An annular extending portion 18 b which axially extends toward the engine side is formed on the inner circumferential portion of the third friction washer 18. The outer circumferential portion of the annular extending portion 18 b is in contact with the inner circumferential end of the clutch plate 3.

The operation of the clutch disc assembly 1′ will now be described.

When the frictional facings 13 are pushed against the flywheel (not shown) on the engine side, the torque of the flywheel on the engine side is inputed to the clutch plate 3 and the retaining plate 4. This torque is transmitted to the hub 2′ through the large coil springs 7, the coil springs 8, the sub-plate 5 and the small coil springs 6 and is further outputed to the shaft (not shown) on the transmission side.

The torsional vibration is transmitted from the flywheel (not shown) on the engine side to the clutch disc assembly 1′ causes the regularly relative rotation between the plates 3 and 4 and the hub 2′. Each of the coil springs 6, 7 and 8 are then compressed. The friction generated causes a hysteresis-like vibration dampening response which is defined by the relationship between the twist angular displacement and the torsional torque is generated in the friction resistance generating mechanism 8.

When a small twist vibration is transmitted from the flywheel (not shown) on the engine side to the clutch disc assembly 1′ producing a small angular displacement, the small coil spring 6 is compressed in the circumferential direction and the first friction washer 14 and the third friction washer 18 is slidably moved along the flange portion 2 b and the projections 2 c of the hub 2′. In this case, the twist vibration of the small angular displacement is effectively attenuated by the characteristics of the low rigidity/low hysteresis torque.

When a relatively large twist vibration which produces a large angular displacement is transmitted to the clutch disc assembly 1′, the small coil springs 6 are compressed and the sub-plate 5 and the hub 2′ are rotated together, a relative rotation is generated between these components and the plates 3 and 4. At this time, the large coil springs 7 and the coil springs 8 are compressed and the first frictional washer 14 is slidably moved along the flange portion 2 b of the hub 2′, the second frictional washer 15 is slidably moved along the side surface on the inner circumferential side of the sub-plate 5, and the third frictional washer 18 is slidably moved along the side surface on the flywheel side of the flange portion 2 b of the hub 2′ and the side surface on the flywheel side of the inner circumferential side of the sub-plate 5. In this embodiment, the urging force of the second conical spring 17 is set to be larger than that of the first conical spring 16 thereby producing the larger friction force. Due to the above-described high rigidity/large friction characteristics, the twist vibration of large angular displacement may be effectively attenuated.

With the above structure, since the proper friction characteristics can be obtained depending on the type of the twist vibration, the clutch disc assembly 1′ can effectively attenuate the twist vibration.

ADVANTAGES OF THE INVENTION

In the spring seat according to the present invention, the phase of the power input rotary element can be made different from that of the power output rotary element in a torsion free state by shifting the first supported surface supported by the power input rotary element with respect to that of the second supported surface supported by the power output rotary element. This method for altering the phase of the power input rotary element and power output rotary element is carried out readily and inexpensively.

Third Embodiment

A clutch disc assembly 100 in accordance with a third embodiment of the present invention is shown in FIGS. 18 through 26. The third embodiment includes many of the features described above with respect to the first and second embodiments and shown in FIGS. 1 through 17. Those elements in the third embodiment with reference numerals common to the reference numerals in the first and second embodiments are generally the same as described above and therefore description thereof will be omitted. Rather, description will be provided only for those elements in the third embodiment which differ or have been modified compared to similar elements in the first and second embodiments.

The clutch disc assembly 100 includes a first spring assembly 7 a and a second spring assembly 7 b. The first spring assembly 7 a is disposed within the diametrically opposing window holes 5 b of the sub-plate 5 and includes the large coil spring (torsion spring) 7 and the small coil spring 58 which is disposed inside the large coil spring 7, as is described above with respect to the first and second embodiments. The second spring assembly 7 b is disposed within diametrically opposing window holes 5 b of the sub-plate 5 and includes a large coil spring 7 and a float rubber 7 c which is disposed inside the large coil spring. The circumferentially opposite ends of the large coil spring 7 of the second spring assembly- 7 b are in contact with the circumferentially opposite ends of the window hole 5 b of the sub-plate 5, the circumferentially opposite ends of the window hole 3 a of the clutch plate 3, and the circumferentially opposite ends of the window hole 4 a of the retaining plate 4. The length of the float rubber 7 c here is shorter than the circumferential length of each window hole. That is, the float rubber 7 c is movable in the circumferential direction between the circumferentially opposite ends of each window hole.

A hysteresis torque generating mechanism 8′ of the third embodiment will now be described with respect to FIGS. 19 through 25. The hysteresis torque generating mechanism 8′ includes many of the elements described above with respect to the first and second embodiments such as the first friction washer 14, the first conical spring 16 and the second conical spring 17. The first conical spring 16 is depicted in FIG. 22 and has been described above. The second conical spring 17 is depicted in FIG. 23 and has been described above. The urging force of the second conical spring 17 is set to be larger than that of the first conical spring 16. The first friction washer 14 is made of, for instance, a nylon-based resin, is depicted in FIGS. 12 and 13 and has been described above.

In other words, in the illustrated embodiment, the hysteresis torque generating mechanism 8′ includes a pair of annular friction elements. One friction element is formed of the first and second friction washers 14 and 15′ (i.e. formed of two pieces coupled together), and the other friction element is formed of the third friction washer 18′. Each friction element has a friction generating surface contacting the sub-plate 5 (first power input element) and another friction generating surface contacting the flange portion 2 b (power output element) of the hub 2. As seen in FIGS. 24 and 25, the first and second friction generating surfaces of each friction element are concentric lie in first and second planes that are generally parallel to one another and spaced apart from one another in an axial direction. Additionally, the first and second friction generating surfaces are concentric with one another.

The hysteresis torque generating mechanism 8′ also includes a second friction washer 15′ which is similar to the second friction washer 15 described above with respect to the second embodiment. The second friction washer 15′ includes the disc portion 15 a, the annular extending portion 15 b, the four recesses 15 e the two snap projections 15 c and the two bar-shaped projections 15 d, as shown in FIGS. 20, 21 and 24. However, in the third embodiment, the second friction washer 15′ also includes a molded portion which includes a friction adjusting element 20. The friction element formed of the first and second friction washers 14 and 15′ has a body portion basically formed of disc portion 15 a, annular extending portion 15 b, disc portion 14 a, annular extending portion 14 b and projections 14 d of friction washers 14 and 15′, with the friction generating surfaces formed thereon. Accordingly, friction washer 14 has one friction generating surface formed thereon and friction washer 15′ has another friction generating surface formed thereon. The friction adjusting element 20 has a higher coefficient of friction than the second friction washer 15′. The friction adjusting element 20 is made of one of the following: a textile blend of rubber based material, a textile blend of resin material, a fiber-glass reinforced material or a ceramic material.

A third friction washer 18′ is included in the hysteresis torque generating mechanism 8′. The third friction washer 18′ is similar to the third friction washer 18 described above with respect to the second embodiment.

The third friction washer 18′ includes the snap projections 18 a, as shown in FIG. 7 (second embodiment). In the third embodiment, shown in FIGS. 19, and 25, the third friction washer 18′ also includes an annular extending portion or body portion 18 c. The outer periphery of the annular extending portion 18 c is in contact with the inner circumferential end of the clutch plate 3. The axially inner periphery of the annular extending portion 18 c is formed with a molded a friction adjusting portion 21, as shown in FIGS. 19 and 25. The friction adjusting portion 21 is constructed from a material having a generally high coefficient of friction, such as a textile blend of rubber based material, a textile blend of resin material, a fiber-glass reinforced material or a ceramic material.

The operation of the clutch disc assembly 100 will now be described.

When the frictional facings 13 are pushed against the flywheel (not shown) on the engine side, the torque of the flywheel on the engine side is inputed into the plates 3 and 4. This torque is transmitted to the hub 2 through the large spring units 7, the sub-plate 5 and the small torsion springs 6 and is further outputed to the shaft (not shown) on the transmission side.

When a small twist vibration is transmitted from the flywheel (not shown) on the engine side to the clutch disc assembly 100 producing a small angular displacement, a relative rotation is generated between the plates 3 and 4 and the sub-plate 5 and the hub 2. At this time, the small torsion springs 6 are repeatedly compressed and expanded in the circumferential direction and the first friction washer 14 and the third friction washer 18′ undergo sliding movement along the flange portion 2 b of the hub 2 and the protrusions 2 c. In this case, the twist vibration of the small angular displacement is effectively attenuated by the characteristics of the low rigidity/low friction (low hysteresis torque).

When a relatively large twist vibration which produces a large angular displacement is transmitted to the clutch disc assembly 100, the small torsion springs 6 are brought into compression and the sub-plate 5 and the hub 2 are then rotated together, a relative rotation is generated between these components and the plates 3 and 4. At this time, the large spring units 7 are repeatedly compressed and expanded in the circumferential direction, so that the first friction washer 14 undergoes sliding movement along the flange portion 2 b of the hub 2, the second friction washer 15′ undergoes sliding movement along the inner circumferential side surface of the sub-plate 5 and the third friction washer 18′ undergoes sliding movement along the side surface on the flywheel side of the flange portion 2 b of the hub 2 and the side surface on the flywheel side of the inner peripheral side of the sub-plate 5. In this case, the urging force of the second conical spring 17 is set to be larger than that of the first conical spring 16, thereby generating a larger friction force. Further, the friction generating surface between the second friction washer 15′ and the sub-plate 5 and the friction generating surface between the third friction washer 18′ and the sub-plate 5 are respectively provided with friction adjusting elements 20 and 21, thereby generating a still larger friction force. Due to the above-described high rigidity/large friction characteristics (large hysteresis torque), the twist vibration of large angular displacement may be effectively attenuated.

In the clutch disc assembly 100, as described above, the appropriate characteristics of the rigidity/friction can be obtained depending on the variation of the twist vibration, so that the clutch disc assembly 100 is effective to attenuate the twist vibrations.

In assembling the clutch disc assembly 100, the first friction washer 14, the second friction washer 15′, the first conical spring 16 and the second conical spring 17 of the hysteresis torque generating mechanism 8′ are previously mounted to the retaining plate 4 to constitute a sub assembly. This mounting operation can be easily carried out by only inserting the snap projections 15 c and bar-shaped projections 15 d of the second washer 15 into the apertures 4 c of the retaining plate 4. The second washer 15′ is engaged with the retaining plate 4 by means of the snap 15 f of the snap projection 15 c, so that respective components are difficult to remove. In this manner, constituting the sub assembly can effect the management of the components as a sub assembly in advance of assembling the whole, thereby facilitating the operation. Also, this enhances operation efficiency in assembling the whole due to the advantage of the sub assembly.

Fourth Embodiment

In the third embodiment described above, the friction adjusting elements are seat members having a high friction coefficient are provided on the friction generating surfaces of each friction washer by molding. However, the friction coefficient of the various friction washers may be configured and adjusted in a variety of arrangements. The configuration for adjusting the friction coefficient is not limited to that in the previous embodiment.

Specifically, in FIG. 26, the damper disc assembly includes the plates 3 and 4. The sub-plate 5 (a first power input element) is disposed between the plates 3 and 4 (second power input element) and is elastically connected to the plates 3 and 4 by a coil spring, as is described above with respect to the third embodiment. The hub 2 is a power output clement that is relatively rotatable with respect to the plates 3 and 4 and with respect to the sub-plate 5, as described above with respect to the third embodiment. The hub 2 also has the flange portion 2 b, as described above. The first friction washer 14 and the second friction washer 15 are disposed between the plate 4 and the combination of the sub-plate 5 and flange portion 2 b of the hub 2. Each of the first and second friction washers is formed with a friction generating surface. The friction generating surface of the first friction washer is in contact with the hub 2, and specifically, the flange portion 2 b of the hub, and the friction generating surface of the second friction washer is in contact with the sub-plate 5 (the first power input element). Each of the first and second friction washers is also formed with engaging portions on a side opposite from the friction generating surface. The engaging portions are configured such that both the first and second friction washers are coupled with the plate 4 (the second power input element) for rotation therewith. The friction generating surface formed on the first friction washer is formed of a material having a coefficient of friction different from that of the friction generating surface formed on the second friction washer. The spring 17 (described above with respect to the third embodiment and FIG. 24) urges the friction generating, surfaces of the first and second friction washers against the flange portion 2 b and the sub-plate 5, respectively.

In a fourth embodiment may be as shown in FIG. 26, for example, where the friction generating surfaces between the flange portions 2 b and the first friction washer 14 and the friction generating surfaces between the flange portions 2 b and the third friction washer 18 are alternatively provided with coatings 25 and 26 to make the friction coefficient of these portions lower than the surface on the second friction washer 15. The coatings 25 and 26 include, for example, zinc or phenolic resin and are formed by flame spray coating. The arrangement may also be that, the friction generating surfaces between the sub-plate 5 and the second friction washer 15 (with contact one another as shown in FIG. 26) and the friction generating surfaces between the sub-plate 5 and the third friction washer 18 (with also contact one another as shown in FIG. 26) are provided with coatings 27 and 28 formed by, for example, flame spray coating in the same manner as in the coatings 25 and 26 to make the friction coefficient of the surfaces defined by the coatings 27 and 28 higher than the surfaces defined by the coatings 25 and 26. Therefore, the friction generating surface of the first friction washer 14 is coated with a material having a first friction coefficient and the friction generating surface of the second friction washer 15 is coated with a material having a second friction coefficient. Further, as is shown in FIG. 26, the second friction washer 15 includes the snap projections 15 c and 15 f which extend through the retaining plate 4 thereby securing the second friction washer 15 thereto for rotation therewith.

For this reason, the small hysteresis torque can be obtained in response to the twist vibration of small amplitude, and the large hysteresis torque can be obtained in response to the twist vibration of large amplitude, thereby effectively attenuating the twist vibration.

The member which stabilizes the friction coefficient can be used as a friction adjusting element. In this case, the friction generating surface can be provided with a coating of, for example, a lubrication member including copper.

ADVANTAGES

As described above, the friction element of resin in accordance with the present invention is provided with a member for adjusting the friction coefficient on its friction generating surface. This result in facilitating the adjustment of the friction coefficient of the friction generating surface. Also the stable friction coefficient can readily be obtained in the friction element of resin.

Further, according to the present invention, the friction coefficient of the friction generating surface of the friction element of resin can readily be adjusted, especially, the shock upon speedup/slowdown can efficiently be attenuated.

Various details of the invention may be changed without departing from its spirit nor its scope. Furthermore, the foregoing description of the embodiments according to the present invention is provided for the purpose of illustration only, and not for the purpose of limiting the invention as defined by the appended claims and their equivalents. 

What is claimed:
 1. A friction element for a damper disc assembly including a first power input element, a second power input element configured for limited relative rotation with respect to the first power input element, and a power output element elastically coupled to the first power input element for limited relative rotary displacement with respect thereto, said friction element comprising: a body portion formed of a resin material having first and second friction generating surfaces formed on a first side of said body portion, said resin material having a first friction coefficient, only one of said first and second friction generating surfaces having a recess formed therein, said first friction generating surface lying in a first plane, said second friction generating surface lying in a second plane, said first and second planes being generally parallel to one another and spaced apart from one another, said first friction generating surface being sized and configured to contact one of the first power input element and the power output element, said second friction generating surface being sized and configured to contact the other of the first power input element and the power output element; an engaging portion formed integrally with said body portion on a second side of said body portion, said engaging portion extending away from said first and second friction generating surfaces, said engaging portion being sized and configured to be coupled to the second power input element; and a friction adjusting element provided in said recess, said friction adjusting element formed of a material having a second friction coefficient different than said first friction coefficient of said resin material of said body portion so that a frictional force generated by said one of said first and second friction generating surfaces having said recess is modified by said friction adjusting element.
 2. The friction element according to claim 1, wherein said second friction coefficient of said friction adjusting element is higher than said first friction coefficient of said resin material of said body portion.
 3. The friction element according to claim 1, wherein said friction adjusting element is molded with said body portion.
 4. The friction element according to claim 1, wherein said engaging portion includes an elastic protrusion that is elastically deformable.
 5. The friction element according to claim 1, wherein said body portion has a generally annular shape, said first and second friction generating surfaces are concentric with one another on said body portion, and said first and second friction generating surfaces are axially offset from one another on said body portion.
 6. The friction element according to claim 1, wherein said body portion comprises two pieces coupled together, one of said two pieces having said first friction generating surface formed thereon and the other of said two pieces having said second friction generating surface formed thereon.
 7. The friction element according to claim 1, wherein said material of said friction adjusting element is selected from the group consisting of: a textile blend of rubber based material, a textile blend of resin material, a fiber-glass re-enforced material and a ceramic material.
 8. A damper disc assembly, comprising: a first power input element; a second power input element configured for limited relative rotation with respect to said first power input element; a power output element disposed adjacent to said first and second power input elements, said power output element elastically coupled to said first power input element for limited relative rotary displacement with respect thereto; and a friction element disposed between said second power input element and said power output element; said friction element comprising a body portion formed of a resin material having first and second friction generating surfaces formed on a first side of said body portion, said resin material having a first friction coefficient, only one of said first and second friction generating surfaces having a recess formed therein, said first friction generating surface lying in a first plane, said second friction generating surface lying in a second plane, said first and second planes being generally parallel to one another and spaced apart from one another; an engaging portion formed integrally with said body portion on a second side of said body portion, said engaging portion extending away from said first and second friction generating surfaces, said engaging portion being connected to said second power input element and said first friction generating surface being in contact with one of said first power input element and said power output element, said second friction generating surface being in contact with the other of said first power input element and said power output element; and a friction adjusting element provided in said recess said friction adjusting element formed of a material having a second friction coefficient different than said first friction coefficient of said resin material of said body portion so that a frictional force generated by said one of said first and second friction generating surfaces having said recess is modified by said friction adjusting element.
 9. The damper disc assembly according to claim 8, wherein said body portion comprises two pieces coupled together, one of said two pieces having said first friction generating surface formed thereon and the other of said two pieces having said second friction generating surface formed thereon.
 10. The damper disc assembly according to claim 8, wherein said friction adjusting element is molded into said first friction generating surface.
 11. The damper disc assembly according to claim 8, wherein said second friction coefficient of said friction adjusting element is higher than said first friction coefficient of said resin material of said body portion.
 12. The damper disc assembly according to claim 8, wherein said material of said friction adjusting element is selected from the group consisting of: a textile blend of rubber based material, a textile blend of resin material, a fiber-glass re-enforced material and a ceramic material.
 13. The damper disc assembly according to claim 8, wherein said friction adjusting element is molded with said body portion.
 14. The damper disc assembly according to claim 8, wherein said engaging portion includes an elastic protrusion that is elastically deformable. 